How to make Princess Zelda Armor : Crown

If you have been researching online to find different ways to make faux armor you will find that craft foam is an extremely easy and cheap way to create realistic looking armor. Is it lightweight and comfortable to wear.
This is the step-by-step process on how to make Princess Zelda Armor. Please understand that is my personal vision of what the armor should look like. As with all of my anime & video game costumes, I put my personal details to make it unique. This pattern is not 100% accurate to the game design. If you are looking to make a exact replica please feel free to draft your own pattern!

If you would like to use my pattern, you can purchase it on my Esty Store (this includes the pattern for Pauldrons, Crown, & Belt). If you would like to use my pattern, you can purchase it for USD $9.99 (this includes the pattern for Pauldrons, Crown, & Belt). The pattern (11 pages) you can print out on standard 8.5 x 11 inch paper. The patterns comes only in one size. The gems I bought from a store in down town LA called Bohemian Crystal years ago.( Im not sure if they still carry them but they might have them on their site!




You will need these items to make the crown:

  • Craft Foam – 3 sheets, 12″ X 18″,  2mm thick
  • Hot Glue Sticks
  • Hot Glue Gun
  • Elmer’s Glue
  • Scissors
  • 12 gauge wire
  • 1 Blue Medium Tear-shaped Gem
  • 1 Blue Medium Triangle-shaped Gem
  • Gold Acrylic Paint
  • Black Acrylic Paint
  • Gold Spray Paint
  • Paint Brushes (Foam & Detail Brushes)
  • Pen or Mechanical Pencil
  • Patience 😉

Where I bought my supplies –

12 gauge wire – Home Depot

Gems – Bohemian Crystal

Craft Foam Sheets,  2mm thick, Hot Glue Sticks, Hot Glue Gun, Elmer’s Glue, Scissors, Gold Acrylic Paint, Black Acrylic Paint, Gold Spray Paint, Paint Brushes (Foam & Detail Brushes), Pen or Mechanical Pencil – Michaels

The Process:

  1. Print the PDF file “Crown”
  2. Cut out pattern.
  3. Lay the pattern on top of the craft foam sheets and trace around shapes, then cut them out.
  4. Measure out the circumference of your head. Add about 4 inches to the length and cut a strip of wire in that size.
  5. Shape the wire around your head then twist the excess together at the back.
  6. Bend the excess wire pointing up. This will serve as a base to glue the back panel to.
  7. Cut a thin strip of craft foam to glue to the inside and outside of your crown. The goal here is to create a nice padding on the inside to protect your head from discomfort and a form to glue the details to on the outside.
  8. Hot glue the leaves together as depicted on the pattern.
  9. Squeeze a line of hot glue in the middle backside of each leaf. This will help renforce the shape.
  10. Trim each leaf cutting the edges to meet smoothy.
  11. Using your hot glue, squeeze out lines to create veins on top of the leaves. (You might want to practice on a scrap piece to get the hang of it)
  12. For the back panel, attach each side with hot glue, using the guide where the arrows meet depicted on the pattern.
  13. Trim the the edges so that the seams blend smoothy.
  14. Reinforce the shape by squeezing lines of hot glue in the back seams.
  15. To create the bevelled edge, draw a line down the center back using a pencil. Place a bead of hot glue and fold together, then hold until it is dry.
  16. Cover each piece with Elmer’s glue & let dry. This will give the acrylic paint a good base to stick to.
  17. The smaller sidewards C shape piece called “Front Crown Detail”  is glued top of the T shaped “Front Crown” piece. After these two pieces are glued together I pressed a line with a pencil down the middle.
  18. Paint all the pieces with the gold acrylic paint. It is up to you how many layers you would like to have and how distressed you want your crown to look. In my example photos, I first did a layer in gold acrylic, then painted all the crevices in black acrylic, then did a light dusting of gold spray paint to give it a bit of metallic shine, thennnnn went over it all again with another layer of gold acrylic paint. It takes a good amount of time, but the more details you put into it, the more dimension your armor will have.
  19. Hot glue your gems in place, then set the large gem by hot gluing the foam detail pieces over it. Paint around the setting in black acrylic to give it more depth.
  20. Glue all the pieces to the wire frame (Front panel, leaves large to small, branch, then back panel). Refer to the sketch on the crown pattern for placement order.
  21. All Done!! One last tip about craft foam: If you ever feel like it is not the right shape you can warm it with a hair dyer to shape it. Heat it until it is super bendy, then hold it in that shape until it cools.

[…] « CosCast Eps 11 How to make Princess Zelda Armor : Crown » […]

Tori Klanjac - May 4, 2012 - 10:54 pm

Do I have to use Paypal? and if so would you be able to send the patterns to this email account. Would it be ok if I used american Express?

Diana - May 14, 2012 - 10:26 am

Thank you so much for sharing this tutorial! Craft foam is great for this kind of props!
I also noticed your wig and If it’s not too much to ask, where did you found it? 🙂

Abs - May 16, 2012 - 11:09 am

I live in an area where our best place for fabrics and costuming supplies closed years ago – now all we have is a mass chain jo-anns or Michaels – is there a good online source for Gems similar to the ones you have used for these costumes – I am in the process of making a comic book one for myself. Thank you.

AuroraTsukari - August 10, 2012 - 4:56 am

Like Abs said above I would love to know where you found the gems. I’ve looked around the internet hoping to keep the price of my costume as cost effective as possible and while extremely pretty real crystal is pricey. Thanks so much and you’ll be hearing from me for an order soon!

Rodrigo - September 20, 2012 - 1:42 am

Are the pattern send by e-mail,right?

Lillyxandra - September 25, 2012 - 11:54 pm

Yes! With in 24 hours

Gabrielle - March 3, 2013 - 2:00 am

This pattern is a godsend for those of us who want to make Princess Zelda costumes. The end result is awesome! However, don’t underestimate the huge time commitment required to complete the crown, belt, and pauldrons. And be aware that this is a very expensive costume to make.

I do have some wishes about the patterns. It would be helpful if 1) the gem sizes were specific (what do small, medium, and large mean?); 2) the photos were numbered to coordinate with the steps in the instructions.

Lillyxandra - March 5, 2013 - 4:38 am

Hello Gabrielle
Thank you for your suggestions. I’ll add dimensions to the suggested gem size and add numbers to the photos!

Kaley - May 6, 2013 - 5:05 pm

Is there any way we could purchase the finished set of crown, belt, and armor from you?

Jennifer Paterson - July 23, 2013 - 12:02 pm

Hi there,
My daughter is having a dress up 21st party in Australia and she wanted to go as princess Zelda. I cut out a pattern myself…..but I could not have done it without your wonderful tutorial photos.
I used all different jewels and crystals to you because I quite simply could not get the ones you used, however craft foam is quite pliable and the jewels should still show through. The armour does take a long time to make so be prepared for that.
Your craft skills are fabulous and we just love your whole website. Your dresses and costumes are beautiful – works of art in fact. Thanks Lillyxandra.

Lillyxandra - July 23, 2013 - 7:43 pm

Thank you so much! I’m happy to hear that the pattern worked for you!!

mrsben - August 15, 2013 - 10:57 am

Extremely creative and a fantastic tutorial! (Learned so much from both …. so thank you.) Regarding making the leaves in on the crown in sections; I’ve seen same done using ‘thinner’ craft foam cut out as one singular piece and the side of an iron is used to shape and crease the vein then … use just the tip of the iron to give (flatten) a nice pointed tip at its end. (Place between two pieces of paper during the process of the latter.) A thin line of glue (or even puffy paint) is then added for the veining if wished.
Hope you do not might me adding the above for the novice who wishes to make a similar version with a less few steps. ☺

Lillyxandra - August 15, 2013 - 4:28 pm

What a fantastic idea! Thank you for sharing!

Taylor - September 30, 2014 - 10:47 pm

So, I think I can solve this jewel problem. I had a heck of a time finding jewels that were the right size, never mind the right color. I looked in four different craft stores and all over the Internet. So instead of ripping my hair out I decided to get creative. For around $15 I was able to make my own jewels in the exact sizes that I needed. At ac Moore I found a candy jewel mould that had just the right size jewels ($2) and with a little two step resin epoxy ($14) I was able to make my own stones. I had on hand some nail polish that was the perfect shade of hylian blue, and painted the flat underneath facet of my clear epoxy jewels, and Ta-Da! Perfect Jewels! The only size the mould did not have was for the two small red stones, but those are such a standard size that just about any craft store. Hope this helps!

Lillyxandra - October 2, 2014 - 4:40 pm

Such a great idea! Thank you for sharing <3

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